This study was undertaken to attempt to achieve a better balance between zirconia coating properties and high-temperature performance by combining the characteristics of coatings obtained from a micro- and a nanostructured feedstock having the same YSZ composition. First, two single-layer coatings were obtained as reference coatings, using the micro- and the nanostructured feedstock, respectively. Four different composite coatings were then obtained by combining these two feedstocks. Two double-layer (multilayer) YSZ coatings were prepared by depositing the microstructured feedstock on the nanostructured layer and vice versa, while two coatings with different particle size gradients (graded coatings) were prepared by depositing various mixtures of the micro- and the nanostructured feedstock in alternate layers. The microstructure and hardness of the resulting coatings were determined. In the multilayer coatings, each layer exhibited a clearly different microstructure, whereas in the graded coatings the microstructural characteristics changed gradually. Coating hardness developed analogously, each layer displaying a marked change in hardness in the multilayer coatings in contrast to a gradual change in the graded coatings. The microstructure and hardness of the individual layers were thus quite well preserved in the developed composite coatings.

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This work was supported by the Spanish Ministry of Science and Innovation (Project MAT2012-38364-C03) and the Research Promotion Plan of Universitat Jaume I,
action 3.1 (Ref. PREDOC/2009/10), and it has been co-funded by the European Regional Development Fund (ERDF). The authors also thank the SCIC of Universitat Jaume I for the FEG-SEM observations.